Modular foundation assembly for beds

ABSTRACT

A modular bed frame has ladder-like side frames with upper and lower side rails, and ladder-like end frames with upper and lower rails. The side and end frames telescopingly attach to the ends of upper and lower rounded corner rails. The insides of the side frames carry tubular upright fittings for increasing vertical rigidity. These fittings also provide upwardly opening tubular sleeves that receive right angle corner connectors on the ends of spaced apart and parallel horizontal slats that traverse the bed frame from end to end when assembled by a user. Separate upright rigid legs with feet on the bottom are slidably attached to downwardly opening tubular sleeves on the underside of the assembled frame structure to elevate the assembled bed foundation above the floor.

FIELD OF THE INVENTION

This invention relates to foundations for use with mattresses in thebedding field, and more particularly, to a modular mattress-supportingfoundation made of metal components easily assembled into a foundationwhich can replace the conventional frame and box spring assembly.

BACKGROUND OF THE INVENTION

Mattress-supporting foundations for conventional box springs are oftenmade of wood frame members with a cloth outer cover. The conventionalbox springs are large and heavy. They require considerable storage spaceand therefore are expensive in stocking in inventory, especially indifferent sizes; and they have a high cost for transporting them fromthe factory to the customer or mattress manufacturer. Improvements arealways sought in the expense of manufacturing, handling, assembling, andtransporting bed foundations, and in the quality of the end product.

The present invention provides a metal bed foundation assemblymanufactured in modular form and capable of being transported andassembled by the customer. The assembly components can be manufacturedat a reasonably low cost while providing a high quality end product. Theassembly avoids the retailer's cost of stocking conventional fullyassembled box springs in inventory and the related higher cost oftransporting them to the retailer or the user.

SUMMARY OF THE INVENTION

Briefly, one embodiment of this invention provides a metal foundationassembly for a bed which comprises a modular system of tubular metalcomponents which are easily assembled into the finished foundation. Thecomponents of the assembly are interconnected by slidably attaching themwith end connectors that engage corresponding connector sleeves so thatthe entire foundation, in one embodiment, can be fully assembled withoutconventional fasteners.

One embodiment of the invention provides a modular foundation assemblyhaving ladder-like side frames with upper and lower side rails andladder-like end frames with upper and lower end rails. Separate cornerconnectors are attached to the ends of the side frames and end frames atthe corners of the assembled foundation. The corner connectors, in oneembodiment, include upper and lower corner rails each formed with aright angle bend. The side and end frames slidably attach to thecorresponding tubular fittings at the ends of upper and lower cornerrails. The assembled corner connectors hold the side frames and endframes together to form a rectangular box-frame structure. The insidesof the side frames carry tubular fittings formed as slat connectorsleeves for connection to slats assembled between the side frames. Theslat connector sleeves receive corner connectors on the ends of spacedapart slats that traverse the width of the box-frame structure whenassembled by the user. The slats extend parallel to one another,perpendicular to the side frames, to provide lateral rigidity betweenthe side frames. Elevating feet can be positioned at least near the fourcorners of the assembled frame structure for elevating the assembledfoundation above the floor. In one embodiment, the elevating feet havingleg sections which are slidably connected to sleeve-like tubularfittings on the undersides of the side frames.

These and other aspects of the invention will be more fully understoodby referring to the following detailed description and the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view showing an assembled metal bedfoundation according to principles of this invention.

FIG. 2 is an end elevational view taken on line 2-2 of FIG. 1.

FIG. 3 is a perspective view showing a corner connector.

FIG. 4 is a perspective view showing an end frame having releasablyattached upper and lower end connectors.

FIG. 5 is a perspective view showing one of a plurality of slats.

FIG. 6 is a fragmentary side elevational view, partly in cross-section,showing a side frame bracing member supporting a upright slat connectorsleeve for releasably receiving an end connector on a slat.

FIG. 7 is a fragmentary end elevational view, partly in cross-section,showing components of the FIG. 6 structure and including a leg connectorsleeve for slidably receiving a leg portion of one of several feet thatsupport the assembled foundation in an elevated position above thefloor.

FIG. 8 is a schematic view illustrating components of a kit formed bythe components of the foundation assembly and a container for shippingthe assembly components in the kit form.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a modular bed foundation assembly 10includes left and right ladder-like side frames 12 and 14 respectively,ladder-like end frames 16, a set of four upper corner connectors 18, anda similar set of four lower corner connectors 20. The corner connectorsare releasably secured to corresponding upper and lower end portions ofthe side frames and adjacent upper and lower end portions of the endframes at the four corners of the assembled foundation. The upper cornerconnectors each releasably connect a corresponding upper end portion ofone of the side frames with an upper end portion of an adjacent endframe. Similarly, the lower corner connectors each releasably connect acorresponding lower end portion of one of the side frames with a lowerend portion of an adjacent end frame. The corner connectors areassembled at the four corners of the foundation to rigidly hold theright and left side frames 12 and 14 in a fixed laterally spaced apartposition, extending parallel to one another, while rigidly holding theend frames 16 in a fixed longitudinally spaced apart position, parallelto one another, at opposite ends of the assembled rectangular box-framefoundation assembly.

The left and right side frames each include corresponding upper andlower elongated tubular rigid metal side members 22 and 24,respectively, spaced apart vertically and extending substantiallyparallel to one another. A plurality of corresponding longitudinallyspaced apart first rigid metal bracing members 26 are affixed in uprightpositions and extend parallel to one another to support the upper andlower tubular side members of each side frame. The first rigid metalbracing members 26 are preferably tubular metal frame members welded atopposite ends to the upper and lower side members.

The left and right end frames 16 each comprise corresponding upper andlower elongated tubular rigid metal end members 28 and 30, respectively,spaced apart vertically and extending parallel to one another. Aplurality of corresponding laterally spaced apart second rigid metalbracing members 32 are rigidly affixed in upright positions extendingparallel to one another for supporting the upper and lower tubular endmembers of each end frame. The second rigid metal bracing members 32 arepreferably tubular metal frame members welded at opposite ends to theupper and lower end members.

Referring to FIG. 3, the corner connectors 18 each comprise a rigidmetal frame member which is tubular in cross-section and bent into agenerally right angle configuration, with a rounded central section. Thestraight end portions of the tubular corner connectors are elongated andextend along mutually perpendicular axes to form the right angleconfiguration. A rigid metal open ended connector sleeve 34 is rigidlyaffixed to one end of each corner connector. A separate open endedconnector sleeve 36 is rigidly affixed to the other end of each cornerconnector. The connector sleeves 34 and 36 are rectangular incross-section so that the interior of the corner sleeve 34 matches therectangular exterior configuration of the upper or lower side members 22or 24. The interior of the connector sleeve 36 matches the rectangularexterior configuration of the upper or lower end members 28 or 30. Thus,during assembly, the upper corner connectors releasably connect endportions of the upper side members to corresponding end portions ofadjacent upper end members, and separate lower corner connectorsreleasably connect end portions of the lower side members tocorresponding end portions of adjacent lower end members. The cornerconnectors in their connected positions, as shown in the assembled formof the foundation in FIG. 1, hold the side frames parallel to oneanother and hold the end frames parallel to one another to form therectangular box-frame profile of the assembled foundation.

FIG. 4 illustrates a partly assembled form of the foundation in whicheach end frame 16 has four corner connectors releasably attached to theupper and lower ends of the end frame, each making a right angle bend sothat the open sleeve portions 34 of the corner connectors face in thedirection to receive the end portions of corresponding side framemembers 22 or 24.

The foundation assembly further includes a plurality of longitudinallyspaced apart tubular rigid metal slats 38 extending parallel to oneanother between the left and right side frames. Each slat includes sideframe connection members 40 at opposite ends of each slat projecting inthe same general direction away from the slat. The slats and theconnection members 40 are preferably rectangular in cross-section. Theside frame connection members 40 extend perpendicular to the axis ofslat 38.

Referring to FIG. 6, each of the first upright bracing members 26carries a separate rigid tubular metal slat connector sleeve 42preferably having a rectangular cross-sectional configuration. The slatconnector sleeves open upwardly and are shaped and sized to slidablyreceive the rectangular shaped and downwardly projecting side frameconnector members 40 at the ends of the slats 38. Thus, in assemblingthe foundation, separate rigid slat connector sleeves 42, which areaffixed to the first bracing members, slidably receive correspondingones of the side frame connection members 40 on the slats. The assembledslats are held in fixed spaced apart positions extending parallel to oneanother between both sides of the side frames and along the length ofthe box-frame formed by the side and end frames of the assembledfoundation. The assembled slats maintain the rigidity of the assembledfoundation.

Referring to FIG. 7, selected ones of the first upright bracing members26 also carry a rigid tubular metal leg connector sleeve 44 having arectangular cross-sectional configuration. The leg connector sleevesopen downwardly to slidably receive separate elevating feet 47 forholding the foundation, in its assembled form, elevated above the floor.The elevating feet comprise a separate upright rigid metal leg member 46of rectangular cross-sectional configuration rigidly affixed to ahorizontally extending foot section 48. The separate leg connectors 44are configured to slidably receive corresponding ones of the leg members46 for rigidly maintaining the leg members in a fixed position tosupport the foundation above the floor. A stop (not shown) is located ineach of the leg connectors 44 to engage the upper end of the leg 46 sothat each of the leg portions of the elevating feet can be spaced auniform distance above the floor when the legs 46 are assembled in theleg connector sleeves 44.

Thus, the invention provides a modular foundation assembly havingladder-like side frames with upper and lower side rails and ladder-likeend frames with upper and lower end rails. The side and end framesslidably attach to the ends of the upper and lower rounded right anglecorner rails. The assembled corner connectors hold the side frames andend frames together to form a rectangular box-frame structure. Theinsides of the side frames carry tubular fittings that provide connectorsleeves that receive corner connectors on the ends of spaced apart slatsthat traverse the width of the box-frame when assembled by the user. Theslats extend parallel to one another, perpendicular to the side frames,to provide lateral rigidity between the side frames. The elevating feetcan be positioned at least near the four corners of the assembled framestructure. The leg portions of the feet are slidably connected to thesocket-like openings in tubular fittings on the undersides of the sideframes. The feet elevate the assembled foundation above the floor.

The following description provides one example of carrying out theprinciples of the invention. The components of the foundation assemblycan be provided so as to form either twin, full or double, queen andking size bed foundations.

Full, double and twin size foundations are approximately 5 to 6 feetlong, queen size is approximately 6 to 6½ feet long, and king size isapproximately 7 feet long. In each instance the slats (and their relatedbracing members on the side frames) have approximately 12 inch spacing.The frame members described below are preferably made of tubular steel,rectangular in cross-section, preferably made from 16 to 19 gauge steel.

The tubular upper and lower side members 22 and 24 of the side framesare ¾×¾ inch square in cross section.

The upper and lower end members 28 and 30 also are preferably ¾×¾ inchsquare in cross section.

The tubular corner connectors 18 are preferably ¾×¾ inch in crosssection. The sleeves 34 and 36 at their ends are approximately ⅞×⅞ inchsquare in cross section.

The first and second bracing members 26 and 32 for the side and endframes are spaced apart by about 12 inches and are approximately ¾×¾inch square in cross section.

For a twin size foundation, the slats 28 and their side frame connectionmembers 40 are ¾×¾ inch in cross section. For full, double, queen orking size foundations, the slats form an integral length of metal tubingeach having an outside dimension of ¾×1½ inches in height and width,respectively. Each slat carries a single ¾×¾ inch side frame connectionmember at each of its ends.

The tubular slat connector sleeves 42 on the upper insides of the leftand right side frames are ⅞×⅞ inch square in cross section.

The leg connector sleeves 44 on the lower insides of the left and rightside frames also are ⅞×⅞ inch square in cross section.

The leg sections 46 of the elevating feet 47 are preferably ¾×¾ inchsquare in cross section.

The height of the first and second bracing members of the side framesand end frames can vary in length between about 3 inches for a lowprofile foundation up to about 8 inches in length for a higher profilefoundation.

FIG. 8 illustrates another form of the invention in which the componentsof the foundation assembly can be contained in kit form. A largerectangular cardboard container (approximately 20 inches wide, 8 inchesin depth, and 7 feet in height) contains the entire assembly of partswhich includes two end frames, two side frames, eight slats, eightcorner connectors and four feet. The kit also includes a cardboard deckand a fabric cover.

The cardboard deck is preferably made of heavy duty cardboard. The deckis scored to be folded as an accordion. The deck is adapted to match thelength and width of the assembled rectangular foundation frame.

The fabric cover fits over the completed foundation (including the deck)akin to a fitted sheet. The inside of the cover and selected componentscan include Velcro fasteners for releasably securing the cover to theassembled foundation.

The container can include a perforated section 52 to be opened forinserting the correctly sized cover that matches the particularfoundation size.

1. A modular bed foundation assembly for supporting a mattress, theassembled foundation comprising: a pair of laterally spaced apart andparallel left and right side frames; a pair of longitudinally spacedapart and parallel left and right end frames; the left and right sideframes each comprising upper and lower elongated tubular rigid metalside members spaced vertically apart and extending substantiallyparallel to one another, and a plurality of longitudinally spaced apartfirst rigid metal bracing members rigidly affixed in upright positionssupporting the upper and lower tubular side members of each side frame;the left and right end frames each comprising upper and lower elongatedtubular rigid metal end members spaced vertically apart and extendingsubstantially parallel to one another, and a plurality of laterallyspaced apart second rigid metal bracing members rigidly affixed inupright positions supporting the upper and lower tubular end members ofeach end frame; separate upper corner connectors each having a generallyright angle profile for slidably connecting end portions of the upperside members to corresponding end portions of adjacent upper endmembers, and separate lower corner connectors each having a generallyright angle profile for slidably connecting end portions of the lowerside members to corresponding end portions of adjacent lower endmembers, the corner connectors in their connected positions rigidlyholding the side frames parallel to one another and the end framesparallel to one another to form a rectangular box-frame profile of theassembled bed foundation; a plurality of longitudinally spaced apartrigid metal slats extending parallel to one another between the left andright side frames, each slat including side frame connection members atopposite ends of each slat projecting in the same general direction awayfrom the slat; separate rigid slat connectors rigidly affixed toselected ones of the first bracing members and configured to slidablyreceive corresponding ones of the side frame connection members on theslats for holding the plurality of slats in fixed spaced apart positionsextending parallel to one another between both sides of the side framesalong the length of the box-frame formed by the assembled side and endframes of the foundation; separate upright rigid metal leg membersadapted for holding the foundation in an elevated substantiallyhorizontal position above a floor; and separate rigid leg connectorsrigidly affixed to selected ones of the first bracing members andconfigured to slidably receive corresponding ones of the leg members forrigidly maintaining the leg members in a fixed position to support thefoundation above the floor.
 2. Apparatus according to claim 1 in whichthe slat connectors are tubular and open upwardly to slidably receivecorrespondingly configured side frame connection members at oppositeends of the slats.
 3. Apparatus according to claim 1 in which the uppercorner connectors and lower corner connectors each include at least onetubular sleeve member at their ends for slidably engaging an end portionof a corresponding side member or end member.
 4. Apparatus according toclaim 1 in which selected ones of the first bracing members include botha slat connector on an upper portion thereof and a leg connector on alower portion thereof.
 5. Apparatus according to claim 1 in which theleg connectors are tubular and open downwardly to slidably receive acorrespondingly configured upper portion of the leg member.
 6. Apparatusaccording to claim 5 including feet affixed to bottom portions of theleg members for resting on the floor.
 7. A modular bed foundationassembly comprising: a pair of left and right side frames; a pair ofleft and right end frames; the left and right side frames eachcomprising upper and lower elongated tubular rigid metal side membersspaced vertically apart and extending substantially parallel to oneanother, and a plurality of longitudinally spaced apart first rigidmetal bracing members rigidly affixed in upright positions supportingthe upper and lower tubular side members of each side frame; the leftand right end frames each comprising upper and lower elongated tubularrigid metal end members spaced vertically apart and extendingsubstantially parallel to one another, and a plurality of laterallyspaced apart second rigid metal bracing members rigidly affixed inupright positions supporting the upper and lower tubular end members ofeach end frame; separate upper corner connectors each having a generallyright angle profile and frame connectors at the ends of the upper cornerconnectors for slidably connecting end portions of the upper sidemembers to corresponding end portions of adjacent upper end members, andseparate lower corner connectors each having a generally right angleprofile and frame connectors at the ends of the upper corner connectorfor slidably connecting end portions of the lower side members; aplurality of longitudinally spaced apart rigid metal slats, each slatincluding side frame connection members at opposite ends of each slatprojecting in the same general direction away from the slat; andseparate rigid slat connectors rigidly affixed to selected ones of thefirst bracing members and configured to slidably receive correspondingones of the side frame connection members on the slats.
 8. Apparatusaccording to claim 7 including separate upright rigid metal leg members;and separate rigid leg connectors rigidly affixed to selected ones ofthe first bracing members and configured to slidably receivecorresponding ones of the leg members.
 9. Apparatus according to claim 7in which the slat connectors are tubular and positioned to slidablyreceive correspondingly configured side frame connection members atopposite ends of the slats.
 10. Apparatus according to claim 7 in whichthe upper corner connectors and lower corner connectors each include atleast one tubular sleeve member at their ends for slidably engaging anend portion of a corresponding side member or end member.
 11. Apparatusaccording to claim 8 in which selected ones of the first bracing membersinclude both a slat connector on an upper portion thereof and a legconnector on a lower portion thereof.
 12. Apparatus according to claim 8in which the leg connectors are tubular and open downwardly to slidablyreceive a correspondingly configured upper portion of the leg member.13. Apparatus according to claim 8 including feet affixed to bottomportions of the leg members for resting on the floor.
 14. A modular bedfoundation assembly in kit form, having components of the foundationassembly disposed in a container, the components comprising: a pair ofleft and right side frames; a pair of left and right end frames; theleft and right side frames each comprising upper and lower elongatedtubular rigid metal side members spaced vertically apart and extendingsubstantially parallel to one another, and a plurality of longitudinallyspaced apart first rigid metal bracing members rigidly affixed inupright positions supporting the upper and lower tubular side members ofeach side frame; the left and right end frames each comprising upper andlower elongated tubular rigid metal end members spaced vertically apartand extending substantially parallel to one another, and a plurality oflaterally spaced apart second rigid metal bracing members rigidlyaffixed in upright positions supporting the upper and lower tubular endmembers of each end frame; separate upper corner connectors each havinga generally right angle profile and frame connectors at the ends of theupper corner connectors for slidably connecting end portions of theupper side members to corresponding end portions of adjacent upper endmembers, and separate lower corner connectors each having a generallyright angle profile and frame connectors at the ends of the lower cornerconnectors for slidably connecting end portions of the lower sidemembers to corresponding end portions of adjacent lower end members; aplurality of longitudinally spaced apart rigid metal slats, each slatincluding side frame connection members at opposite ends of each slatprojecting in the same general direction away from the slat; separaterigid slat connectors rigidly affixed to selected ones of the firstbracing members and configured to slidably receive corresponding ones ofthe side frame connection members on the slats; separate upright rigidmetal leg members; and separate rigid leg connectors rigidly affixed toselected ones of the first bracing members and configured to slidablyreceive corresponding ones of the leg members.
 15. Apparatus accordingto claim 14 in which the container includes a fabric cover shaped to fita rectangular foundation assembled from the components.
 16. Apparatusaccording to claim 14 in which the container includes a foldable deck.